Absorbent Article Process and Apparatus for Intermittently Deactivating Elastics in Elastic Laminates

ABSTRACT

The present disclosure relates to methods and apparatuses for assembling absorbent articles, and more particularly, methods and apparatuses for severing elastic in an advancing elastic laminate. A continuous elastic laminate may be formed by bonding elastic strands between a first continuous substrate layer and a second continuous substrate layer. As discussed in more detail below, the continuous elastic laminate may advance through a cutting apparatus that intermittently deactivates or severs the elastic strands of the elastic laminate along the machine direction.

FIELD OF THE INVENTION

The present disclosure relates to apparatuses and methods formanufacturing absorbent articles, and more particularly, methods andapparatuses for deactivating elastic in an advancing laminate.

BACKGROUND OF THE INVENTION

Along an assembly line, various types of articles, such as for example,diapers and other absorbent articles, may be assembled by addingcomponents to and otherwise modifying an advancing, continuous web ofmaterial. For example, in some processes, advancing webs of material arecombined with other advancing webs of material. In other examples,individual components created from advancing webs of material arecombined with advancing webs of material, which in turn, are thencombined with other advancing webs of material. Webs of material andcomponent parts used to manufacture diapers may include: backsheets,topsheet, absorbent cores, front and/or back ears, fastener components,and various types of elastic webs and components such as leg elastics,barrier leg cuff elastics, and waist elastics. Once the desiredcomponent parts are assembled, the advancing web(s) and component partsare subjected to a final knife cut to separate the web(s) into discretediapers or other absorbent articles. The discrete diapers or absorbentarticles may also then be folded and packaged.

Various methods and apparatuses may be used for attaching differentcomponents to the advancing web and/or otherwise modify the advancingweb. Some production operations are configured to construct elasticlaminates including elastics bonded with the one or more substratesadvancing in a machine direction. The operations may be furtherconfigured to cut and/or otherwise deactivate discrete lengths of theelastics. In some operations, an elastic laminate may advance through acutting station that cuts the elastic in the advancing laminate.However, some current configurations have certain drawbacks. Forexample, some present cutting apparatuses may cause unintended damage tothe elastic laminate, such as by severing the substrate while cuttingthe elastic. In addition, the blades on some current cutting apparatusesmay be susceptible to wear after relatively short operating periods.Such blade wear may manifest itself in inconsistent elastic cutting.Further, it may be relatively expensive to repair worn cutting devices.Consequently, it would be beneficial to provide elastic cutting methodsand apparatuses that are configured to provide relatively consistentcutting of elastics without excessive and/or unintentional damage to thesubstrate. It would also be beneficial to provide elastic cuttingmethods and apparatuses that are less susceptible to blade wear and thatmay be configured for ease of repair at relatively low costs.

SUMMARY OF THE INVENTION

The present disclosure relates to methods and apparatuses for assemblingabsorbent articles, and more particularly, methods and apparatuses forsevering elastic in an advancing elastic laminate. A continuous elasticlaminate may be formed by bonding elastic strands between a firstcontinuous substrate layer and a second continuous substrate layer. Asdiscussed in more detail below, the continuous elastic laminate mayadvance through a cutting apparatus that intermittently deactivates orsevers the elastic strands of the elastic laminate along the machinedirection.

In one form, a method for severing elastic strands in an elasticlaminate includes the steps of: advancing a continuous first substratelayer and a continuous second substrate layer in a machine direction;stretching an elastic strand in the machine direction; bonding thestretched elastic strand between the first substrate layer and thesecond substrate layer to form a continuous elastic laminate; advancingthe elastic laminate in the machine direction through a nip definedbetween a cutting roll and an anvil roll, the cutting roll rotatingaround a first axis of rotation and the anvil roll rotating around asecond axis of rotation, wherein the anvil roll includes an outercircumferential surface defining a minimum distance D1 between the outercircumferential surface and first axis of rotation, wherein the cuttingroll includes a blade having a distal edge defining a maximum distanceD2 between the distal edge and the first axis of rotation, and whereinthe D2 is greater than D1; deflecting the distal edge of the blade by aninterference distance, wherein the interference distance is equal to orgreater than a difference between D2 and D1; and severing the elasticstrand by pressing the distal edge of the blade against the elasticlaminate in the nip.

In another form, an apparatus for severing elastic strands in an elasticlaminate includes: an anvil roll including an outer circumferentialsurface; a cutting roll adjacent the anvil roll to define a nip betweenthe anvil roll and the cutting roll, the cutting roll adapted to rotateabout a first axis of rotation, wherein the outer circumferentialsurface and first axis of rotation are separated by a minimum distanceD1; a blade connected with the cutting roll, the blade having a distaledge, and wherein the distal edge and the first axis of rotation areseparated by a distance D2, wherein D2 is greater than D1 and definingan interference distance equal to the difference between D2 and D1; andwherein the distal edge of the blade is adapted to deflect theinterference distance when moving through the nip.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a diaper pant.

FIG. 2A is a partially cut away plan view of the diaper pant shown inFIG. 1.

FIG. 2B is a partially cut away plan view of a second embodiment of adiaper pant.

FIG. 3A is a cross-sectional view of the diaper pants of FIGS. 2A and 2Btaken along line 3A-3A.

FIG. 3B is a cross-sectional view of the diaper pants of FIGS. 2A and 2Btaken along line 3B-3B.

FIG. 4 is a schematic side view of a cutting apparatus adapted to severelastics in an advancing elastic laminate.

FIG. 5A is a view of the elastic laminate from FIG. 4 taken along line5A-5A.

FIG. 5A1 is a cross-sectional view of the elastic laminate from FIG. 5Ataken along line A1-A1.

FIG. 5A2 shows a detailed view of a belt substrate with the firstsubstrate layer cut-away.

FIG. 5B is a view of continuous the advancing elastic laminate from FIG.4 taken along line 5B-5B.

FIG. 5B1 is a cross-sectional view of the elastic laminate from FIG. 5Btaken along line B1-B1 showing elastics cut in non-bonded regions.

FIG. 5B2 shows a detailed view of the belt substrate from FIG. 5B withthe first substrate layer cut-away to illustrate elastics after havingbeen cut in the non-bonded regions.

FIG. 5B1A is a cross-sectional view of the elastic laminate from FIG. 5Btaken along line B1-B1 showing elastics and first substrate layer cut innon-bonded regions.

FIG. 5B1B is a cross-sectional view of the elastic laminate from FIG. 5Btaken along line B1-B1 showing elastics, the first substrate layer, andthe second substrate layer cut in non-bonded regions.

FIG. 5B1C is a cross-sectional view of the elastic laminate from FIG. 5Btaken along line B1-B1 with the first substrate layer and the secondsubstrate layer bonded together by the cutting device.

FIG. 6 is a perspective view of an embodiment of a cutting apparatus.

FIG. 7 is a front side view of the cutting apparatus of FIG. 6 as twoblades are rotated toward two substrates partially wrapped around ananvil roll.

FIG. 8A is a left side view of the cutting apparatus of FIG. 7 showingthe blade initiating contact with the substrate partially wrapped aroundthe anvil roll.

FIG. 8B shows the cutting apparatus of FIG. 8A as the blade flexes whilebeing rotated into contact with the substrate partially wrapped aroundthe anvil roll.

FIG. 8C shows the cutting apparatus of FIG. 8B after the blade isrotated away from the substrate partially wrapped around the anvil roll.

FIG. 9A is a detailed side view of a cutting apparatus and an embodimentof a blade assembly.

FIG. 9B is a detailed isometric view of the blade assembly of FIG. 9A.

FIG. 9C is a detailed side view of a blade including a flat distal edge.

FIG. 9D is a detailed side view of a blade including a beveled distaledge.

FIG. 9E is a detailed side view of a blade including a curved distaledge.

FIG. 10A is a detailed side view of a cutting apparatus and anembodiment of a blade assembly.

FIG. 10B is a side view of the blade assembly of FIG. 10A.

FIG. 10C is an isometric view of an embodiment of a blade having acylindrical shape.

FIG. 11A is a detailed side view of a cutting apparatus and anembodiment of a blade assembly.

FIG. 11B is a detailed isometric view of the blade assembly of FIG. 11A.

FIG. 11C is an isometric view of an embodiment of a blade having abeveled distal edge.

FIG. 11D is an isometric view of an embodiment of a blade having acurved distal edge.

FIG. 11E is an isometric view of an embodiment a blade assembly having asupport member that may be included with the blade assemblies of FIGS.11A and 11B.

DETAILED DESCRIPTION OF THE INVENTION

The following term explanations may be useful in understanding thepresent disclosure:

“Absorbent article” is used herein to refer to consumer products whoseprimary function is to absorb and retain soils and wastes. “Diaper” isused herein to refer to an absorbent article generally worn by infantsand incontinent persons about the lower torso. The term “disposable” isused herein to describe absorbent articles which generally are notintended to be laundered or otherwise restored or reused as an absorbentarticle (e.g., they are intended to be discarded after a single use andmay also be configured to be recycled, composted or otherwise disposedof in an environmentally compatible manner).

An “elastic,” “elastomer” or “elastomeric” refers to materialsexhibiting elastic properties, which include any material that uponapplication of a force to its relaxed, initial length can stretch orelongate to an elongated length more than 10% greater than its initiallength and will substantially recover back to about its initial lengthupon release of the applied force.

As used herein, the term “joined” encompasses configurations whereby anelement is directly secured to another element by affixing the elementdirectly to the other element, and configurations whereby an element isindirectly secured to another element by affixing the element tointermediate member(s) which in turn are affixed to the other element.

“Longitudinal” means a direction running substantially perpendicularfrom a waist edge to a longitudinally opposing waist edge of anabsorbent article when the article is in a flat out, uncontracted state,or from a waist edge to the bottom of the crotch, i.e. the fold line, ina bi-folded article. Directions within 45 degrees of the longitudinaldirection are considered to be “longitudinal.” “Lateral” refers to adirection running from a longitudinally extending side edge to alaterally opposing longitudinally extending side edge of an article andgenerally at a right angle to the longitudinal direction. Directionswithin 45 degrees of the lateral direction are considered to be“lateral.”

The term “substrate” is used herein to describe a material which isprimarily two-dimensional (i.e. in an XY plane) and whose thickness (ina Z direction) is relatively small (i.e. 1/10 or less) in comparison toits length (in an X direction) and width (in a Y direction).Non-limiting examples of substrates include a web, layer or layers orfibrous materials, nonwovens, films and foils such as polymeric films ormetallic foils. These materials may be used alone or may comprise two ormore layers laminated together. As such, a web is a substrate.

The term “nonwoven” refers herein to a material made from continuous(long) filaments (fibers) and/or discontinuous (short) filaments(fibers) by processes such as spunbonding, meltblowing, carding, and thelike. Nonwovens do not have a woven or knitted filament pattern.

The term “machine direction” (MD) is used herein to refer to thedirection of material flow through a process. In addition, relativeplacement and movement of material can be described as flowing in themachine direction through a process from upstream in the process todownstream in the process.

The term “cross direction” (CD) is used herein to refer to a directionthat is generally perpendicular to the machine direction.

The term “pant” (also referred to as “training pant”, “pre-closeddiaper”, “diaper pant”, “pant diaper”, and “pull-on diaper”) refersherein to disposable absorbent articles having a continuous perimeterwaist opening and continuous perimeter leg openings designed for infantor adult wearers. A pant can be configured with a continuous or closedwaist opening and at least one continuous, closed, leg opening prior tothe article being applied to the wearer. A pant can be preformed byvarious techniques including, but not limited to, joining togetherportions of the article using any refastenable and/or permanent closuremember (e.g., seams, heat bonds, pressure welds, adhesives, cohesivebonds, mechanical fasteners, etc.). A pant can be preformed anywherealong the circumference of the article in the waist region (e.g., sidefastened or seamed, front waist fastened or seamed, rear waist fastenedor seamed.

“Pre-fastened” refers herein to pant diapers manufactured and providedto consumers in a configuration wherein the front waist region and theback waist region are fastened or connected to each other as packaged,prior to being applied to the wearer. As such pant diapers may have acontinuous perimeter waist opening and continuous perimeter leg openingsdesigned for infant or adult wearers. As discussed in more detail below,a diaper pant can be preformed by various techniques including, but notlimited to, joining together portions of the diaper using refastenableand/or permanent closure members (e.g., seams, heat bonds, pressurewelds, adhesives, cohesive bonds, mechanical fasteners, etc.). Inaddition, pant diapers can be preformed anywhere along the circumferenceof the waist region (e.g., side fastened or connected, front waistfastened or connected, rear waist fastened or connected).

The present disclosure relates to methods and apparatuses for assemblingabsorbent articles, and more particularly, methods and apparatuses forsevering elastic in an advancing elastic laminate. A continuous elasticlaminate may be formed by bonding elastic strands between a firstcontinuous substrate layer and a second continuous substrate layer. Itis to be appreciated the elastic laminate can be formed in various ways.For example, in some embodiments, the first continuous substrate layermay be formed from a first continuous substrate, and the secondcontinuous substrate layer may be formed from a second continuoussubstrate. In other embodiments, the first continuous substrate layerand the second continuous substrate layer may be formed by a foldingportion of a single continuous substrate onto another portion of thesingle continuous substrate. As discussed in more detail below, thecontinuous elastic laminate may advance through a cutting apparatus thatintermittently deactivates or severs the elastic strands of the elasticlaminate along the machine direction.

In some embodiments, the elastic laminate may include the elasticstrands that are intermittently bonded between substrate layers alongthe machine direction. As such, the elastic laminate may include bondedregions and non-bonded regions intermittently spaced along the machinedirection, wherein the elastic strands are bonded to either the firstsubstrate layer or the second substrate layer in bonded regions, andwherein the elastic strands are not bonded to either the first substratelayer or the second substrate layer in the non-bonded regions. Theelastic strands may then be intermittently deactivated by severing thestrands in the non-bonded regions of the continuous elastic laminate. Assuch the elastic laminate may include elastic regions and deactivatedregions, wherein the elastic regions of the elastic laminate correspondwith the bonded regions. And the deactivated regions of the elasticlaminate may correspond with the non-bonded regions.

The processes and apparatuses discussed herein may be used to assembleelastic laminates in various types of substrate configurations, some ofwhich may be used in the manufacture of different types of absorbentarticles. To help provide additional context to the subsequentdiscussion of the process embodiments, the following provides a generaldescription of absorbent articles in the form of diapers that mayinclude elastic laminates that may be assembled in accordance with themethods and apparatuses disclosed herein. Although the methods andapparatuses herein are discussed below in the context of manufacturingabsorbent articles, it is to be appreciated that the assembly methodsand apparatuses herein may be configured to manufacture various types ofsubstrates having intermittently spaced elastic and inelastic regions.

FIGS. 1 and 2A show an example of a diaper 100 that may include elasticlaminates assembled in accordance with the apparatuses and methodsdisclosed herein. In particular, FIG. 1 shows a perspective view of adiaper pant 100 in a pre-fastened configuration, and FIG. 2A shows aplan view of the diaper pant 100 with the portion of the diaper thatfaces away from a wearer oriented towards the viewer. The diaper pant100 shown in FIGS. 1 and 2A includes a chassis 102 and a ring-likeelastic belt 104. As discussed below in more detail, a first elasticbelt 106 and a second elastic belt 108 are connected together to formthe ring-like elastic belt 104.

With continued reference to FIG. 2A, the chassis 102 includes a firstwaist region 116, a second waist region 118, and a crotch region 119disposed intermediate the first and second waist regions. The firstwaist region 116 may be configured as a front waist region, and thesecond waist region 118 may be configured as back waist region. In someembodiments, the length of each of the front waist region, back waistregion, and crotch region may be ⅓ of the length of the absorbentarticle 100. The diaper 100 may also include a laterally extending frontwaist edge 120 in the front waist region 116 and a longitudinallyopposing and laterally extending back waist edge 122 in the back waistregion 118. To provide a frame of reference for the present discussion,the diaper 100 and chassis 102 of FIG. 2A is shown with a longitudinalaxis 124 and a lateral axis 126. In some embodiments, the longitudinalaxis 124 may extend through the front waist edge 120 and through theback waist edge 122. And the lateral axis 126 may extend through a firstlongitudinal or right side edge 128 and through a midpoint of a secondlongitudinal or left side edge 130 of the chassis 102.

As shown in FIGS. 1 and 2A, the diaper pant 100 may include an inner,body facing surface 132, and an outer, garment facing surface 134. Thechassis 102 may include a backsheet 136 and a topsheet 138. The chassis102 may also include an absorbent assembly 140 including an absorbentcore 142 may be disposed between a portion of the topsheet 138 and thebacksheet 136. As discussed in more detail below, the diaper 100 mayalso include other features, such as leg elastics and/or leg cuffs toenhance the fit around the legs of the wearer.

As shown in FIG. 2A, the periphery of the chassis 102 may be defined bythe first longitudinal side edge 128, a second longitudinal side edge130; a first laterally extending end edge 144 disposed in the firstwaist region 116; and a second laterally extending end edge 146 disposedin the second waist region 118. Both side edges 128 and 130 extendlongitudinally between the first end edge 144 and the second end edge146. As shown in FIG. 2A, the laterally extending end edges 144 and 146are located longitudinally inward from the laterally extending frontwaist edge 120 in the front waist region 116 and the laterally extendingback waist edge 122 in the back waist region 118. When the diaper pant100 is worn on the lower torso of a wearer, the front waist edge 120 andthe back waist edge 122 of the chassis 102 may encircle a portion of thewaist of the wearer. At the same time, the chassis side edges 128 and130 may encircle at least a portion of the legs of the wearer. And thecrotch region 119 may be generally positioned between the legs of thewearer with the absorbent core 142 extending from the front waist region116 through the crotch region 119 to the back waist region 118.

It is to also be appreciated that a portion or the whole of the diaper100 may also be made laterally extensible. The additional extensibilitymay help allow the diaper 100 to conform to the body of a wearer duringmovement by the wearer. The additional extensibility may also help, forexample, allow the user of the diaper 100 including a chassis 102 havinga particular size before extension to extend the front waist region 116,the back waist region 118, or both waist regions of the diaper 100and/or chassis 102 to provide additional body coverage for wearers ofdiffering size, i.e., to tailor the diaper to an individual wearer. Suchextension of the waist region or regions may give the absorbent articlea generally hourglass shape, so long as the crotch region is extended toa relatively lesser degree than the waist region or regions, and mayimpart a tailored appearance to the article when it is worn.

As previously mentioned, the diaper pant 100 may include a backsheet136. The backsheet 136 may also define the outer surface 134 of thechassis 102. The backsheet 136 may be impervious to fluids (e.g.,menses, urine, and/or runny feces) and may be manufactured from a thinplastic film, although other flexible liquid impervious materials mayalso be used. The backsheet 136 may prevent the exudates absorbed andcontained in the absorbent core from wetting articles which contact thediaper 100, such as bedsheets, pajamas and undergarments. The backsheet136 may also comprise a woven or nonwoven material, polymeric films suchas thermoplastic films of polyethylene or polypropylene, and/or amulti-layer or composite materials comprising a film and a nonwovenmaterial (e.g., having an inner film layer and an outer nonwoven layer).The backsheet may also comprise an elastomeric film. An examplebacksheet 136 may be a polyethylene film having a thickness of fromabout 0.012 mm (0.5 mils) to about 0.051 mm (2.0 mils). Exemplarypolyethylene films are manufactured by Clopay Corporation of Cincinnati,Ohio, under the designation BR-120 and BR-121 and by Tredegar FilmProducts of Terre Haute, Ind., under the designation XP-39385. Thebacksheet 136 may also be embossed and/or matte-finished to provide amore clothlike appearance. Further, the backsheet 136 may permit vaporsto escape from the absorbent core (i.e., the backsheet is breathable)while still preventing exudates from passing through the backsheet 136.The size of the backsheet 136 may be dictated by the size of theabsorbent core 142 and/or particular configuration or size of the diaper100.

Also described above, the diaper pant 100 may include a topsheet 138.The topsheet 138 may also define all or part of the inner surface 132 ofthe chassis 102. The topsheet 138 may be compliant, soft feeling, andnon-irritating to the wearer's skin. It may be elastically stretchablein one or two directions. Further, the topsheet 138 may be liquidpervious, permitting liquids (e.g., menses, urine, and/or runny feces)to penetrate through its thickness. A topsheet 138 may be manufacturedfrom a wide range of materials such as woven and nonwoven materials;apertured or hydroformed thermoplastic films; apertured nonwovens,porous foams; reticulated foams; reticulated thermoplastic films; andthermoplastic scrims. Woven and nonwoven materials may comprise naturalfibers such as wood or cotton fibers; synthetic fibers such aspolyester, polypropylene, or polyethylene fibers; or combinationsthereof. If the topsheet 138 includes fibers, the fibers may bespunbond, carded, wet-laid, meltblown, hydroentangled, or otherwiseprocessed as is known in the art.

Topsheets 138 may be selected from high loft nonwoven topsheets,apertured film topsheets and apertured nonwoven topsheets. Aperturedfilm topsheets may be pervious to bodily exudates, yet substantiallynon-absorbent, and have a reduced tendency to allow fluids to pass backthrough and rewet the wearer's skin. Exemplary apertured films mayinclude those described in U.S. Pat. Nos. 5,628,097; 5,916,661;6,545,197; and 6,107,539.

As mentioned above, the diaper pant 100 may also include an absorbentassembly 140 that is joined to the chassis 102. As shown in FIG. 2A, theabsorbent assembly 140 may have a laterally extending front edge 148 inthe front waist region 116 and may have a longitudinally opposing andlaterally extending back edge 150 in the back waist region 118. Theabsorbent assembly may have a longitudinally extending right side edge152 and may have a laterally opposing and longitudinally extending leftside edge 154, both absorbent assembly side edges 152 and 154 may extendlongitudinally between the front edge 148 and the back edge 150. Theabsorbent assembly 140 may additionally include one or more absorbentcores 142 or absorbent core layers. The absorbent core 142 may be atleast partially disposed between the topsheet 138 and the backsheet 136and may be formed in various sizes and shapes that are compatible withthe diaper. Exemplary absorbent structures for use as the absorbent coreof the present disclosure are described in U.S. Pat. Nos. 4,610,678;4,673,402; 4,888,231; and 4,834,735.

Some absorbent core embodiments may comprise fluid storage cores thatcontain reduced amounts of cellulosic airfelt material. For instance,such cores may comprise less than about 40%, 30%, 20%, 10%, 5%, or even1% of cellulosic airfelt material. Such a core may comprises primarilyabsorbent gelling material in amounts of at least about 60%, 70%, 80%,85%, 90%, 95%, or even about 100%, where the remainder of the corecomprises a microfiber glue (if applicable). Such cores, microfiberglues, and absorbent gelling materials are described in U.S. Pat. Nos.5,599,335; 5,562,646; 5,669,894; and 6,790,798 as well as U.S. PatentPublication Nos. 2004/0158212 and 2004/0097895.

As previously mentioned, the diaper 100 may also include elasticized legcuffs 156. It is to be appreciated that the leg cuffs 156 can be and aresometimes also referred to as leg bands, side flaps, barrier cuffs,elastic cuffs or gasketing cuffs. The elasticized leg cuffs 156 may beconfigured in various ways to help reduce the leakage of body exudatesin the leg regions. Example leg cuffs 156 may include those described inU.S. Pat. Nos. 3,860,003; 4,909,803; 4,695,278; 4,795,454; 4,704,115;4,909,803; and U.S. Patent Publication No. 2009/0312730A1.

As mentioned above, diaper pants may be manufactured with a ring-likeelastic belt 104 and provided to consumers in a configuration whereinthe front waist region 116 and the back waist region 118 are connectedto each other as packaged, prior to being applied to the wearer. Assuch, diaper pants may have a continuous perimeter waist opening 110 andcontinuous perimeter leg openings 112 such as shown in FIG. 1.

As previously mentioned, the ring-like elastic belt 104 is defined by afirst elastic belt 106 connected with a second elastic belt 108. Asshown in FIG. 2A, the first elastic belt 106 defines first and secondopposing end regions 106 a, 106 b and a central region 106 c, and thesecond elastic 108 belt defines first and second opposing end regions108 a, 108 b and a central region 108 c.

The central region 106 c of the first elastic belt is connected with thefirst waist region 116 of the chassis 102, and the central region 108 cof the second elastic belt 108 is connected with the second waist region118 of the chassis 102. As shown in FIG. 1, the first end region 106 aof the first elastic belt 106 is connected with the first end region 108a of the second elastic belt 108 at first side seam 178, and the secondend region 106 b of the first elastic belt 106 is connected with thesecond end region 108 b of the second elastic belt 108 at second sideseam 180 to define the ring-like elastic belt 104 as well as the waistopening 110 and leg openings 112.

As shown in FIGS. 2A, 3A, and 3B, the first elastic belt 106 alsodefines an outer lateral edge 107 a and an inner lateral edge 107 b, andthe second elastic belt 108 defines an outer lateral edge 109 a and aninner lateral edge 109 b. The outer lateral edges 107 a, 109 a may alsodefine the front waist edge 120 and the laterally extending back waistedge 122. The first elastic belt and the second elastic belt may alsoeach include an outer, garment facing layer 162 and an inner, wearerfacing layer 164. It is to be appreciated that the first elastic belt106 and the second elastic belt 108 may comprise the same materialsand/or may have the same structure. In some embodiments, the firstelastic belt 106 and the second elastic belt may comprise differentmaterials and/or may have different structures. It should also beappreciated that the first elastic belt 106 and the second elastic belt108 may be constructed from various materials. For example, the firstand second belts may be manufactured from materials such as plasticfilms; apertured plastic films; woven or nonwoven webs of naturalmaterials (e.g., wood or cotton fibers), synthetic fibers (e.g.,polyolefins, polyamides, polyester, polyethylene, or polypropylenefibers) or a combination of natural and/or synthetic fibers; or coatedwoven or nonwoven webs. In some embodiments, the first and secondelastic belts include a nonwoven web of synthetic fibers, and mayinclude a stretchable nonwoven. In other embodiments, the first andsecond elastic belts include an inner hydrophobic, non-stretchablenonwoven material and an outer hydrophobic, non-stretchable nonwovenmaterial.

The first and second elastic belts 106, 108 may also each include beltelastic material interposed between the outer layer 162 and the innerlayer 164. The belt elastic material may include one or more elasticelements such as strands, ribbons, or panels extending along the lengthsof the elastic belts. As shown in FIGS. 2A, 3A, and 3B, the belt elasticmaterial may include a plurality of elastic strands 168 which may bereferred to herein as outer, waist elastics 170 and inner, waistelastics 172.

As shown in FIG. 2A, the outer, waist elastics 170 extend continuouslylaterally between the first and second opposing end regions 106 a, 106 band across the central region 106 c of the first elastic belt 106 andbetween the first and second opposing end regions 108 a, 108 b andacross the central region 108 c of the second elastic belt 108. In someembodiments, some elastic strands 168 may be configured withdiscontinuities in areas. For example, as shown in FIG. 2A, the inner,waist elastics 172 extend intermittently along the first and secondelastic belts 106, 108. More particularly, the inner, waist elastics 172extend along the first and second opposing end regions 106 a, 106 b andpartially across the central region 106 c of the first elastic belt 106.The inner, waist elastics 172 also extend along the first and secondopposing end regions 108 a, 108 b and partially across the centralregion 108 c of the second elastic belt 108. As such, the inner, waistelastics 172 do not extend across the entirety of the central regions106 c, 108 c of the first and second elastic belts 106, 108. Thus, someelastic strands 168 may not extend continuously through regions of thefirst and second elastic belts 106, 108 where the first and secondelastic belts 106, 108 overlap the absorbent assembly 140. In someembodiments, some elastic strands 168 may partially extend into regionsof the first and second elastic belts 106, 108 where the first andsecond elastic belts 106, 108 overlap the absorbent assembly 140. Insome embodiments, some elastic strands 168 may not extend into anyregion of the first and second elastic belts 106, 108 where the firstand second elastic belts 106, 108 overlap the absorbent assembly 140. Itis to be appreciated that the first and/or second elastic belts 106, 108may be configured with various configurations of discontinuities in theouter, waist elastics 170 and/or the inner, waist elastic elastics 172.

In some embodiments, the elastic strands 168 may be disposed at aconstant interval in the longitudinal direction. In other embodiments,the elastic strands 168 may be disposed at different intervals in thelongitudinal direction. As discussed in more detail below, the beltelastic strands 168, in a stretched condition, may be interposed andjoined between the uncontracted outer layer and the uncontracted innerlayer. When the belt elastic material is relaxed, the belt elasticmaterial returns to an unstretched condition and contracts the outerlayer and the inner layer. The belt elastic material may provide adesired variation of contraction force in the area of the ring-likeelastic belt.

It is to be appreciated that the chassis 102 and elastic belts 106, 108may be configured in different ways other than as depicted in FIG. 2A.For example, FIG. 2B shows a plan view of a diaper pant 100 having thesame components as described above with reference to FIG. 2A, except thefirst laterally extending end edge 144 of the chassis 102 is alignedalong and coincides with the outer lateral edge 107 a of the firstelastic belt 106, and the second laterally extending end edge 146 isaligned along and coincides with the outer lateral edge 109 a of thesecond belt 108.

As previously mentioned, the apparatuses and methods according to thepresent disclosure may be utilized to assemble elastic laminates 300used in various components of absorbent articles, such as for example,elastic belts 106, 108 and/or leg cuffs 156. Although the followingmethods may be provided in the context of the diaper 100 shown in FIGS.1 and 2A, it is to be appreciated that elastic laminates can be usedwith various embodiments of diapers manufactured according the methodsdisclosed herein, such as for example, the absorbent articles disclosedin U.S. Pat. No. 7,569,039, filed on Nov. 10, 2004; U.S. PatentPublication No. 2005/0107764A1, filed on Nov. 10, 2004; U.S. patentapplication Ser. No. 13/221,127, filed on Aug. 30, 2011; and U.S. patentapplication Ser. No. 13/221,104, filed on Aug. 30, 2011, which are allhereby incorporated by reference herein.

FIG. 4 shows a schematic view of a cutting apparatus 500 adapted tosever elastic strands 302 in a continuous elastic laminate 300 advancingin a machine direction MD. It is to be appreciated that the cuttingapparatus 500 may be adapted to cut elastics 302 in various differentconfigurations of elastic laminates 300. For example, with reference toFIGS. 4, 5B, 5B1, and 5B2, the continuous elastic laminate 300 enteringthe cutting apparatus 500 may include a first substrate layer 304, asecond substrate layer 306, and elastic strands 302 bonded between thefirst substrate layer 304 and the second substrate layer 306. In oneexample, the elastic laminate 300 may correspond with the elastic belts106, 108 discussed above. Thus, the first substrate layer 304 maycorrespond with the inner layer 162; the second substrate layer maycorrespond with the outer layer 164; and the elastics 302 may correspondwith the elastics 168, 170, 172 discussed above. As previouslymentioned, the first continuous substrate layer 304 may be formed from afirst continuous substrate, and the second continuous substrate layer306 may be formed from a second continuous substrate. In someembodiments, the first continuous substrate layer 304 and the secondcontinuous substrate layer 306 may be formed by a folding portion of asingle continuous substrate onto another portion of the singlecontinuous substrate, sandwiching the elastics 302 therebetween.

As shown in FIGS. 4 and 5A, the elastic laminate 300 may include firstelastic strands 302 a and second elastic strands 302 b that arestretched in the machine direction MD and bonded with the firstsubstrate layer 304 and/or the second substrate layer 306. Moreparticularly, the first elastic strands 302 a may be continuously bondedwith the first substrate layer 304 and/or the second substrate layer 306with adhesive along the machine direction MD. And the second elasticstrands 302 b may be intermittently bonded with the first substratelayer 304 and/or the second substrate layer 306 with adhesive along themachine direction MD. Thus, as shown in FIG. 5A, the elastic laminate300 may include non-bonded regions 403 intermittently spaced betweenbonded regions 405 along the machine direction MD. Thus, the secondelastic strands 302 b are not bonded to either the first substrate layer304 or the second substrate layer 306 in the non-bonded regions 403. Andthe second elastic strands 302 b are bonded to the first substrate layer304 and/or second substrate layer 306 in the bonded regions 405. For thepurposes of clarity, dashed lines 401 are shown in FIGS. 5A, 5B, andothers to represent example boundaries between the non-bonded regions403 and the bonded regions 405. It is to be appreciated that suchboundaries between the non-bonded regions 403 and the bonded regions 405can also be curved, angled, and/or straight. As discussed in more detailbelow with reference to FIGS. 5A2 and 5B2, although the second elasticstrands 302 b are not bonded to the either the first substrate layer 304or the second substrate layer 306 in the non-bonded regions 403,adhesive 504 may be applied in areas between the individual secondelastic strands 172 to bond the first substrate layer 304 and secondsubstrate layer 306 together in the non-bonded regions 403.

As shown in FIG. 4, the elastic laminate 300 advances in the machinedirection MD to the cutting unit 500. The cutting unit 500 thenintermittently deactivates the elastics 302 in the elastic laminate 300.More particularly, the cutting unit 500 may sever, cut, and/or break thesecond elastics 302 b in the non-bonded regions 403 of the elasticlaminate 300. As shown in FIGS. 5B, 5B1, and 5B2, severed ends 404 ofthe second elastics 302 b retract or snap back to the bonded regions 405of the elastic laminate 300. In some embodiments, such as shown in FIGS.5C1 and 5C2, the cutting unit 500 may be configured to sever only theelastics 300 b in the non-bonded regions 403 of the elastic laminatewithout cutting through either the first substrate layer 304 or thesecond substrate layer 306. In other configurations, the cutting unit500 may be configured to cut the elastics 302 b in the non-bondedregions 403 of the elastic laminate 300 while also cutting through oneor both the first substrate layer 304 and the second substrate layer306. For example, FIG. 5B1A shows a configuration where the cutting unit500 cuts slits 413 through the second substrate layer 306 while cuttingthe elastics 302 b in the non-bonded regions 403 of the elastic laminate300, without cutting through the first substrate layer 304. In anotherexample, FIG. 5B1B shows a configuration where the cutting unit 500 cutsslits 413 through both the second substrate layer 306 and the firstsubstrate layer 304 while cutting the elastics 302 b in the non-bondedregions 403 of the elastic laminate 300.

As previously discussed, the second elastic strands 302 b are not bondedto the either the first substrate layer 304 or second substrate layer306 in the non-bonded regions 403. However, it is to be appreciated thatthe non-bonded regions 403 and bonded regions 405 may be configured withvarious adhesive applications. For example, in some configurations, thefirst substrate layer 304 and the second substrate layer 306 may not bebonded together in the non-bonded regions 403. In some configurations,adhesive may be applied to bond the first substrate layer 304 and thesecond substrate layer 306 together in the non-bonded regions 403. Forexample, FIG. 5A2 shows a detailed view of an elastic laminate 300 withthe first substrate layer 306 cut-away to illustrate an embodiment ofadhesive application in the bonded regions 405 and the non-bondedregions 403. More particularly, FIG. 5A2 shows an example adhesiveapplication configuration wherein adhesive 504A has been applied to thefirst and second substrate layers 304, 306 and/or elastics 302 b in thebonded regions 405, and wherein adhesive 504B has been applied either orboth substrate layers 304, 306, and not the elastics 302 b, in thenon-bonded regions 403. As such, adhesive 504A may be intermittentlyapplied along the machine direction MD in the bonded regions 405, andadhesive 504B may be intermittently applied along the machine directionin the non-bonded regions 403. Further, as shown in FIGS. 5A2 and 5B2,adhesive 504C may be continuously applied to the substrate layers 304,306 and/or elastics 300 a in the bonded regions 405 and non-bondedregions 403.

With continued reference to FIG. 5A3, adhesive 504A may be applied instrips along the elastics 302 b extending the machine direction MD inthe bonded regions 405. As such, the adhesive 504A bonds the firstsubstrate layer 304, the second substrate layer 306, and the elastics302 b together in the bonded regions 405. In addition, adhesive 504B maybe applied in strips between the elastics 302 b extending the machinedirection MD in the non-bonded regions 403. As such, the adhesive 504Bbonds the first substrate layer 304 and the second substrate layer 306together in the non-bonded regions 403. Further, strips of the adhesive504B do not bond the elastics 302 b to either the first substrate layer304 or the second substrate layer 306 in the non-bonded regions 403.FIG. 5B3 shows a detailed view of the elastic laminate 300 from FIG. 5A3with the first substrate layer 304 cut-away to illustrate the elastics302 b after having been cut in the non-bonded regions 403 wherein thesevered ends 404 of the elastics 302 b have retracted or snapped back tothe bonded regions 405. As such, the elastic laminate 300 may includeelastic regions 405 a and deactivated regions 403 a, wherein the elasticregions 405 a of the elastic laminate 300 may correspond with the bondedregions 405. And the deactivated regions 403 a of the elastic laminate300 may correspond with the non-bonded regions 403.

Although an example elastic laminate 300 is described herein that mayinclude elastic strands 302 intermittently bonded to define non-bondedregions 403 and bonded regions 405, it is to be appreciated that theapparatuses and methods herein may be configured to sever elasticstrands 302 in other types of elastic laminate configurations. Forexample, some elastic laminates 300 may include elastic strands 302continuously bonded with a first substrate layer 304 and a secondsubstrate layer 306, and the cutting apparatus may sever thecontinuously bonded elastic strands 302 intermittently along the machinedirection MD to define elastic regions 405 a separated by deactivatedregions 403 a. More particularly, the elastic strands 302 may beintermittently deactivated by cutting the elastic strands 302 into oneor more discrete pieces to define the deactivated regions 403 a of theelastic laminate 300. In other examples, the cutting units 500 andmethods herein may be configured to operate cut elastics in accordancewith the methods and apparatuses disclosed in U.S. Patent Applicationentitled “APPARATUSES AND METHODS FOR MAKING ABSORBENT ARTICLES”, filedon Mar. 30, 2012, which may be further identified by Attorney Docket No.12390; U.S. Patent Application entitled “APPARATUSES AND METHODS FORMAKING ABSORBENT ARTICLES”, filed on Mar. 30, 2012, which may be furtheridentified by Attorney Docket No. 12391; U.S. Patent Applicationentitled “APPARATUSES AND METHODS FOR MAKING ABSORBENT ARTICLES”, filedon Mar. 30, 2012, which may be further identified by Attorney Docket No.12392; U.S. Patent Application entitled “APPARATUSES AND METHODS FORMAKING ABSORBENT ARTICLES”, filed on Mar. 30, 2012, which may be furtheridentified by Attorney Docket No. 12393; and U.S. Patent Applicationentitled “METHODS AND APPARATUSES FOR MAKING LEG CUFFS FOR ABSORBENTARTICLES”, filed on Mar. 30, 2012, which may be further identified byAttorney Docket No. 12395, all of which are incorporated by referenceherein.

It is to be appreciated that various configurations of cutting units 510can be used with the apparatuses and methods herein. For example, thecutting units may be configured with a flexible cutting bladearrangement. FIGS. 6 and 7 show an example embodiment of a cutting unit500 including a cutting roll 600 and an anvil roll 602. The cutting roll600 is adapted to rotate around an axis of rotation 604 and defines anouter circumferential surface 606. And the anvil roll 602 is adapted torotate around an axis of rotation 608 and defines an outercircumferential surface 610. The cutting roll 600 is adjacent to theanvil roll 602 and create a nip 603 defined by a minimum distance, D,between the outer circumferential surface 606 of the cutting roll 602and the outer circumferential surface 610 of the anvil roll 602. Asshown in FIGS. 6 and 7, the cutting roll 600 may also include one ormore blades 612. Each blade 612 may have a proximal end portion 614extending in a cross direction (CD) a length, L, along the outercircumferential surface 606 of the cutting roll 600. The blades 612 maydefine a dimension, H1, extending from the proximal end portion 614 to adistal edge 616. In addition, from the proximal end portion 614, theblades may extend radially outward from the outer circumferentialsurface 606 of the cutting roll 600 to the distal edge 616 by adistance, H. It is to be appreciated that the blades 612 may extendradially outward from the outer circumferential surface 606 to define anangle of 90 degrees or less, such as about 45 degrees, between the blade612 and a tangential plane intersecting the proximal end portion 614 onthe outer circumferential surface 606. As such, in some embodiments, H1may be equal to H, and in some embodiments, H1 may be greater than H. Asshown in FIGS. 6 and 7, the blades 612 may define a rectangular shapehaving a first surface 618 and an opposing second surface 620 separatedby a thickness, t. The blades 612 may have a small thickness, t,relative to the distance, H1, such that blades 612 are flexible orbendable.

As shown in FIGS. 6-8C, the cutting unit 500 may be arranged such thatthe first and second elastic laminates 300 advance in a machinedirection MD to partially wrap around the outer circumferential surface610 of the anvil roll 602. As the anvil roll 602 and the cutting roll600 rotate, portions of the first surfaces 618 and the distal edges 616of the blades 612 are moved into contact with the elastic laminates 300,such as shown in FIG. 8A. As shown in FIGS. 8A-8C, the distance, H, ofeach blade 612 is greater than the distance, D, between the cutting roll600 and the anvil roll 602. Thus, with reference to FIG. 8B, as theblades 612 rotate though the nip 603 between the cutting roll 600 andthe anvil roll 602, the blades 612 flex or bend inward along the secondsurface 620. As such, portions of the first surfaces 618 and/or thedistal edges 616 of the blades 612 exert pressure on the elasticlaminates 300 to sever the elastics 302, such as for example, elastics302 b in non-bonded regions 403 discussed above. Referring now to FIG.8C, as the cutting roll 600 continues to rotate, the blades 612 moveaway from the nip 603 and straighten back out along the distance, H1,thus returning to the original blade shapes before entering the nip 603.

It is to be appreciated that the elastic laminates 300 may be arrangedin various ways on the cutting unit 500. For example, as shown in FIGS.6-8C, the elastic laminates 300 may advance in the machine direction MDto partially wrap around the rotating anvil roll 602 such that the firstsubstrate layer 304 is in contact with the outer circumferential surface610 of the anvil roll 602. As such, the blades 612 of the rotatingcutting roll 600 contact the second substrate layers 306 of the elasticlaminates 300 while advancing through the nip 603. It is to beappreciated that the elastic laminates 300 may be arranged such thateither the first substrate layer 304 or the second substrate layer 306is in contact with the outer circumferential surface 610 of the anvilroll 602. For example, in some embodiments, the elastic laminates 300may be arranged to partially wrap around the rotating anvil roll 602such that the first substrate layer 304 are in contact with the outercircumferential surface 610 of the anvil roll 602. As discussed above,the cutting unit 500 shown in FIGS. 6-8C may be configured to sever onlythe elastics 302 b in the non-bonded regions 403 of the elasticlaminates 300 without cutting through either the first substrate layer304 or the second substrate layer 306. In other configurations, thecutting unit 500 may be configured to cut the elastics 302 b in thenon-bonded regions 403 of the elastic laminates 300 while also cuttingthrough one or both the first substrate layer 304 and the secondsubstrate layer 306.

As discussed above, the blades 612 of the cutting unit 500 exertpressure on the elastic laminates 300 to sever the elastics 302. In someembodiments, the pressure exerted by the blades 612 may also create apressure bond between the first substrate layer 303 and the secondsubstrate layer 306. For example, in embodiments wherein the first andsecond substrate layers 302, 306 comprise the outer layer belt material162 and the inner layer belt material 164, both including nonwoven webs,the distal edges 616 of the blades 612 may exert enough pressure on thenonwoven webs to melt and fuse some of the nonwoven fibers together,thus creating a bond 613 between the outer layer belt material 162 andthe inner layer belt material 164. Embodiments of the bond 613 are shownin FIG. 5B1C. A shown in FIG. 1, the bond 613 may be visible in theelastic belt 104 of the diaper 100, and may correspond with a shape ofthe distal edge 616 of the blade 612.

It is to be appreciated that the cutting unit 500 may be configured withvarious quantities of blades having various shapes and orientations. Forexample, the cutting unit 500 shown in FIGS. 6-8C includes four blades612 a, 612 b, 612 c, 612 d. The first and second blades 612 a, 612 b maybe located 180 degrees apart from the third and fourth blades 612 c, 612d on the outer circumferential surface 606 of the cutting roll 600. Itis to be appreciated that the cutting roll may also be configured withvarious numbers of blades arranged circumferentially along the outercircumferential surface 606 of the cutting roll 600. The proximal endportions 614 of the first blade 612 a and the second blade 612 b mayalso be aligned with each other and with the axis of rotation 604 so asto extend in a straight line in the cross direction (CD) perpendicularto the machine direction (MD). Similarly, proximal end portions 614 ofthe third blade 612 c and the fourth blade 612 d may be aligned witheach other and with the axis of rotation 604 so as to extend in astraight line in the cross direction (CD) perpendicular to the machinedirection (MD). In addition, the first blade 612 a and the second blade612 b, as well as the third and fourth blades 612 c, 612 d, may definedifferent lengths, L, and may separated from each other by variousdistances in the cross direction CD. For example, the lengths, L, of theblades 612 are configured such so as to engage portions of the elasticlaminates 300 so as to cut the elastics 300 b without cutting elastics300 a. In addition, the blades 612 may be configured to cut the elastics300 b simultaneously in the CD direction along a substantially straightline. It is also to be appreciated that the cutting roll 600 may beconfigured with more than or less than two blades 612 aligned along theCD direction of outer circumferential surface 606 of the cutting roll600. For example, in some embodiments, instead of having the first blade612 a and the second blade 612 b, the cutting roll 600 may be configuredwith a single blade 612 extending along the CD direction for a length,L, on the outer circumferential surface 606. Although the cutting unit500 is shown in FIG. 6 as cutting elastics in two elastic laminates 300,it should also be appreciated that the cutting unit 500 may beconfigured to cut elastics less than or more than two elastic laminates.

It is to be appreciated that the cutting unit 500 such as describedabove and as shown in FIG. 6 may include various blade assemblyconfigurations, wherein the cutting units are configured with aninterference distance between the anvil roll and the cutting roll 600 orthe blades 612. Some example blade configurations are described in moredetail below with reference to FIGS. 9A-11D. As discussed in more detailbelow, the interference distance causes distal edges 616 of the blades612 to deflect when moving through the nip 603 between the anvil roll602 and the cutting roll 600. As such, the deflection causes the distaledges 616 of the blades 612 exert pressure on the elastic laminates 300advancing through the nip 603 and sever the elastics 302. As the cuttingroll 600 continues to rotate and the blades 612 move away from the nip603, the distal edges 616 of the blades 612 return to positions prior tobeing deflected upon entering the nip 603. As discussed in more detailbelow, the blade assemblies may configured in various ways to allow thedistal edges 616 of the blades 612 to deflect. For example, in someembodiments, the blade assemblies may include blades that are adapted tobend or flex. In other embodiments, the blade may be connected withsprings or other types of flexible supports that allow the distal edgesof the blades to deflect. In yet other embodiments, the blade assembliesmay include both flexible or bendable blades connected with springs orother types of flexible supports.

As previously discussed above and as shown in FIGS. 9A, 10A, and 11A,the cutting roll 600 is adjacent to the anvil roll 602 and create a nip603 defined by a minimum distance, D, between the outer circumferentialsurface 606 of the cutting roll 602 and the outer circumferentialsurface 610 of the anvil roll 602. The blades 612 may extend radiallyoutward from the outer circumferential surface 606 of the cutting roll600 to the distal edge 616 by a distance, H. And the distance, H, ofeach blade 612 is greater than the distance, D, between the cutting roll600 and the anvil roll 602, creating an interference distance betweenthe distal edges 616 of the blades 612 and the outer circumferentialsurface 610 of the anvil roll 602. As such, in some embodiments theinterference distance may be defined by the difference between thedistance, H, and the distance, D. As shown in FIG. 8C, it is to beappreciated that the interference distance between the blade 612 and theanvil roll 602 for the apparatuses and methods herein may also bedefined with reference to a distance, D1, and a distance, D2, wherein D2is greater than D1. With continued reference to FIG. 8C, the distance,D1, is the minimum distance between the axis of rotation 604 of thecutting roll 600 and the outer circumferential surface 610 of the anvilroll 602. And the distance, D2, is the maximum distance between the axisof rotation 604 of the cutting roll 600 and the distal edge 616 of theblade 612. As such, the interference distance may be defined by thedifference between the distance, D2, and the distance, D1. In someembodiments, the interference distance may be 5 μm or greater.

As shown in FIGS. 9A and 9B, the cutting unit 500 may include a bladeassembly 622 having a blade 612 connected with a support member 624. Insome embodiments, the support member 624 may be configured as a discretepiece that is releasably or permanently connected with cutting roll 600.In other embodiments, the support member 624 may configured as anintegral part of the cutting roll 600. As shown in FIG. 9A, the supportmember 624 may include a first, base, portion 624 a and a second,mounting, portion 624 b. The mounting portion 624 b may be connectedwith the base portion 624 a to form a substantially L-shaped side view.As shown in FIG. 9B, the blade 612 may be connected with mountingportion 624 b. Referring back to FIG. 9A, the blade 612 may extendradially outward from the support portion 624 a of the support member624 by a distance, H2. It is to be appreciated that the blade 612 may bereleasably connected with the support member 624 in various ways, suchas for example, with fasteners 626 in the form of bolts or screws. Insome embodiments, the blade may be permanently connected with or madeintegral with the support member 624 or cutting roll 600.

With continued reference to FIG. 9A, as the blades 612 move though thenip 603 between the cutting roll 600 and the anvil roll 602, theinterference distance may cause the blades 612 to flex or bend in adirection generally indicated by the arrow labeled as Dirt. As such, thedistal edges 616 of the blades 612 may exert pressure on the elasticlaminates 300 advancing through the nip 603 and sever the elastics 302as discussed above. As the cutting roll 600 continues to rotate and theblades 612 move away from the nip 603 and returning to the originalblade shapes before entering the nip 603 by flexing or bending back in adirection generally indicated by the arrow labeled as Dir2. It is to beappreciated that the forces the blade 612 exerts on the elastic laminate300 advancing through the nip 603 may be affected by various parameters,such as for example: the blade material; the distance, H2, by which theblade extends from the base member; and the thickness, t, of the blade612.

It is also to be appreciated that the blade 616 shown in FIGS. 9A and 9Bmay have differently shaped distal edges 616. For example, the blade 612may include a flat distal edge 616, such as shown in FIG. 9C. In anotherexample, the blade 616 may include a beveled distal edge 616, such asshown in FIG. 9D. And in yet another example, the blade 616 may includea curved distal edge 616, such as shown in FIG. 9E. The curved distaledge may be defined by a radius, r1. In some embodiments, the radius,r1, may be from about 50 μm to about 4000 μm.

FIGS. 10A and 10B show another embodiment of a blade assembly 622 thatmay be used with the cutting unit 500. As shown in FIGS. 10A and 10B,the blade assembly 622 may include a blade 612 connected with a supportmember 624. The blade assembly 622 may also include spring members 630that connect the support member 624 with the cutting roll 602. Asdiscussed below, the spring members 630 may compress and/or bend toallow the blade 612 to deflect when moving through the nip 603. As shownin FIGS. 10A-10C, the blade 612 may be cylindrically shaped and may bereleasably connected with support member 624. The curved outercircumference of the cylindrically shaped blade may defined by a radius,r1, such as shown in FIG. 10C. In some embodiments, the radius, r1, maybe from about 50 μm to about 4000 μm. It is also to be appreciated thatthe blade 616 shown in FIGS. 10A and 10B may have differently shapeddistal edges 616, such as for example, a flat distal edge or a beveleddistal edge.

With continued reference to FIG. 10A, as the blades 612 move though thenip 603 between the cutting roll 600 and the anvil roll 602, theinterference distance may cause the spring members 630 to compressand/or bend, which in turn, allows the blades 612 to deflect indirections generally indicated by the arrows labeled as Dir1. As such,the compression and/or deformation of the spring members 630 causes thedistal edges 616 of the blades 612 to exert pressure on the elasticlaminates 300 advancing through the nip 603 and sever the elastics 302as discussed above. As the cutting roll 600 continues to rotate and theblades 612 move away from the nip 603, the spring members 630 return tothe original uncompressed states before entering the nip 603, which maycause the blades 612 to move in directions generally indicated by thearrows labeled as Dir2. It is to be appreciated that the forces theblade 612 exerts on the elastic laminate 300 advancing through the nip603 may be affected by the spring constants and other parameters of thespring members 630. It is to be appreciated that the spring members 630may be configured in various ways. For example, in some embodiments, thespring members 630 are configured as machined springs, such as forexample, various types of machined springs available from HelicalProducts, Inc.

FIGS. 11A and 11B show yet another embodiment of a blade assembly 622that may be used with the cutting unit 500. As shown in FIGS. 11A and11B, the blade assembly 622 may include a blade 612 connected with asupport member 624. The support member 624 may include a first, base,portion 624 a; a second, mounting, portion 624 b; and a third, flexible,flexile portion 624 c. As illustrated, the flexible portion 624 cconnects the mounting portion 624 b with the base portion 624 a. Theblade 612 may be positioned on mounting portion 624 b and held in placewith clamps 632 releasably connected with the mounting portion 624 b. Asdiscussed below, the flexible portion 624 c of may flex and/or bend toallow the blade 612 to deflect when moving through the nip 603. As shownin FIGS. 11A-11C, the blade 612 may have a beveled distal edge 616. Inanother embodiment, such as shown in FIG. 11D, the blade 612 may have acurved distal edge 616 may defined by a radius, r1. In some embodiments,the radius, r1, may be from about 50 μm to about 4000 μm. In yet otherembodiments, the support member 624 shown in FIGS. 11A and 11B may beadapted to hold a blade 612 that is cylindrically shaped, such asdiscussed above with reference to FIG. 10C. FIG. 11E shows a bladeassembly 624 having a support member 624 with flexible portion 624 cthat is relatively narrower than the full length of the blade 612 aswell as the first and second portions 624 a, 624 b, and as such,provides additional flexibility for severing elastics even there ismisalignment between the knife roll and the anvil.

With continued reference to FIG. 11A, as the blades 612 move though thenip 603 between the cutting roll 600 and the anvil roll 602, theinterference distance may cause the flexible portion 624 c of thesupport member to flex or bend, which in turn, allows the blades 612 todeflect in directions generally indicated by the arrows labeled as Dir1.As such, the bending and/or deformation of the flexible portion 624 ccauses the distal edges 616 of the blades 612 to exert pressure on theelastic laminates 300 advancing through the nip 603 and sever theelastics 302 as discussed above. As the cutting roll 600 continues torotate and the blades 612 move away from the nip 603, the flexibleportions 624 c of the support members 624 return to the originaluncompressed states before entering the nip 603, which may cause theblades 612 to move back in directions generally indicated by the arrowslabeled as Dir2. It is to be appreciated that the forces the blade 612exerts on the elastic laminate 300 advancing through the nip 603 may beaffected by the spring constants and other parameters of the flexibleportion 624 c of the support member 624.

It is to be appreciated that various embodiments of blade assemblyconfigurations having flexible blades and/or flexible support membersand/or springs have been disclosed herein. Such blade assemblyconfigurations may provide relatively more simple machine design andfabrication requirements than those that may be required for otherdesigns, such as rigid die cutter designs. For example, the presentlydisclosed blade assembly configurations may provide for greaterflexibility in knife set-up and may reduce the level of precision thatwould otherwise be required for rigid die cutter configurations.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. An apparatus for severing elastic strands in anelastic laminate, the apparatus comprising: an anvil roll including anouter circumferential surface; a cutting roll adjacent the anvil roll todefine a nip between the anvil roll and the cutting roll, the cuttingroll adapted to rotate about a first axis of rotation, wherein the outercircumferential surface and first axis of rotation are separated by aminimum distance D1; a blade connected with the cutting roll, the bladehaving a distal edge, and wherein the distal edge and the first axis ofrotation are separated by a distance D2, wherein D2 is greater than D1and defining an interference distance equal to the difference between D2and D1; and wherein the distal edge of the blade is adapted to deflectthe interference distance when moving through the nip and wherein theblade bends when the distal edge deflects by the interference distance.2. The apparatus of claim 1, wherein the cutting roll comprises an outercircumferential surface; wherein the anvil roll comprises an outercircumferential surface; and wherein the nip is defined by a minimumdistance, D, between the outer circumferential surface of the cuttingroll and the outer circumferential surface of the anvil roll.
 3. Theapparatus of claim 2, wherein the blade extends radially outward fromthe outer circumferential surface of the cutting roll to define an angleof 90 degrees between the blade and a tangential plane intersecting theproximal end portion on the outer circumferential surface.
 4. Theapparatus of claim 2, wherein the blade extends radially outward fromthe outer circumferential surface of the cutting roll to define an angleof less than 90 degrees between the blade and a tangential planeintersecting the proximal end portion on the outer circumferentialsurface.
 5. The apparatus of claim 2, wherein the blade comprises aproximal end portion extending axially for a length, L, along the outercircumferential surface of the cutting roll; and wherein the bladedefines a distance, H1, extending from the proximal end portion to thedistal edge.
 6. The apparatus of claim 5, wherein the blade extendsradially outward from the outer circumferential surface of the cuttingroll to the distal edge by a distance, H, and wherein H1 is equal to H.7. The apparatus of claim 6, wherein H is greater than D.
 8. Theapparatus of claim 5, wherein the blade extends radially outward fromthe outer circumferential surface of the cutting roll to the distal edgeby a distance, H, and wherein H1 is greater than H.
 9. The apparatus ofclaim 8, wherein H is greater than D.
 10. The apparatus of claim 5,wherein the blade comprises a first surface and an opposing secondsurface separated by a thickness, t, wherein the thickness is smallerthan the distance, H1.
 11. The apparatus of claim 5, wherein the distaledge of the blade is curved.
 12. The apparatus of claim 11, wherein thecurved distal edge is defined by a radius of about 50 μm to about 4000μm.
 13. The apparatus of claim 5, wherein the distal edge of the bladeis flat.
 14. The apparatus of claim 1, wherein the blade is connectedwith a support member.
 15. The apparatus of claim 14, wherein thesupport member is connected with a spring, and the spring is connectedwith the cutting roll.
 16. The apparatus of claim 14, wherein thesupport member bends when the distal edge deflects by the interferencedistance.
 17. The apparatus of claim 14, wherein the spring iscompressed radially inward toward the first axis of rotation when thewhen the distal edge deflects by the interference distance.
 18. Theapparatus of claim 17, wherein the spring bends when the when the distaledge deflects by the interference distance.
 19. The apparatus of claim14, wherein the blade is releasably connected with the support member.20. The apparatus of claim 1, wherein the interference distance is atleast 5 μm.